Developing functional test programs for hardware testing is time-consuming and experience-wise. A functional test program’s quality is usually assessed only through expensive fault simulation campaigns during early development. This paper presents indirect quality measurements of fault detection capabilities of functional test programs to reduce the total cost of fault simulation in the early development stages. We present a methodology that analyzes the instruction trace generated by running functional test programs on-chip and building its control and dataflow graph. We use the graph to identify potential flaws that affect the program’s fault detection capabilities. We present different graph-based techniques to measure the programs’ quality indirectly. By exploiting standard debugging formats, we individuate instructions in the source code that affect the graph-based measurements. We perform experiments on an automotive device manufactured by STMicroelectronics, running functional test programs of different natures. Our results show that our metric allows test engineers to develop better functional test programs without basing their development solely on fault simulation campaigns.

This paper explores the trade-offs of reducing scan test patterns during Wafer Sort, accepting additional packaging costs, and screening more chips during Package Tests. Previous works proposed ways of selecting or reordering patterns to bring the most efficient to the left. Unlike such studies, this work quantifies the benefit of removing patterns directly from the tail of any pattern set. The paper elaborates on novel formulas to propose a comprehensive cost model that combines yield, Wafer Sort, packaging, and Package Test costs. The model evolves from known concepts by assuming that mass production defectivity is non-uniformly distributed over the die population and accounts for sacrificial lots to extract guiding information. It is shown that reducing patterns at Wafer Sort is beneficial under certain conditions of yield, fault coverage, and considering equipment and production costs. The model accurately estimates the number of patterns to remove for maximum gain in these cases. As a further by-product, the paper shows that a significant cost advantage can be achieved if pattern generation is guided based on the basics of the non-uniform failure distribution. This approach is validated with an academic benchmark and by observing six months of production for a real-world microcontroller by STMicroelectronics.

Electronics play a significant role in modern society in various areas of our daily lives. Companies producing embedded nano-electronic systems have responded to the ever-increasing demand for high-performance chips with the development and production of structurally complex design, both in terms of the number of gates they are composed of and how they are arranged on the silicon surface. Especially devices intended for safety-critical fields, such as the Automotive field, require a thorough and precise testing process before they are fielded. This paper proposes a correlation analysis between candidate faulty logical gates as possible sources of a given failure identified during the Manufacturing Test Flow and their layout characteristics on the silicon. It is meaningful feedback for manufacturers about the quality of their applied tests. The experimental results are reported for data regarding a production lot of an Automotive System-on-Chip belonging to the SPC58 family produced by STMicroelectronics.

Testing and validation check a hardware device or a software application against the desired design requirements. They are a vital part of all steps of system engineering and typically account for a significant percentage of the overall development cost. This paper presents a novel technique to provide a quick preliminary evaluation of functional test procedures of various natures, ranging from Software-Based Self-Test to Burn-In Functional Stress and System-level tests. We define a new metric called “connectivity”, which is fast to compute and can be used to guide functional program development. The method does not require logic or fault simulations, and it is based on the analysis of the execution trace generated by the functional program. To summarize our process, we first obtain the trace directly from the chip, running the software through a debugger. Then, we create a graph representation of the program data flow. Finally, we analyze the graph to identify instructions that negatively impact the final coverage. We perform experiments on an automotive device manufactured by STMicroelectronics, and we demonstrate the effectiveness of the approach in terms of computation time and beneficial effects on the fault coverage.